Vapor permeable retroreflective garment

ABSTRACT

The disclosure describes vapor permeable retroreflective material for use on protective garments. The material may be formed in a non-continuous pattern that provides a high-level of retroreflective brightness, yet also provides adequate permeability to prevent exposure to trapped thermal energy and heated moisture. The non-continuous retroreflective pattern may include retroreflective regions and non-retroreflective regions arranged such that thermal decay through the protective garment is not substantially decreased in the regions corresponding to the retroreflective material. Rather, vapor permeation and thermal decay through the garment may be substantially the same as if the retroreflective material was not present.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of U.S. patent application Ser. No. 11/839,782;which is a continuation of U.S. patent application Ser. No. 11/598,616,filed Nov. 13, 2006, abandoned; which is a continuation of U.S. patentapplication Ser. No. 11/365,944, filed Mar. 1, 2006, abandoned; which isa continuation of U.S. patent application Ser. No. 11/183,027, filedJul. 15, 2005, issued as U.S. Pat. No. 7,107,622; which is acontinuation of U.S. patent application Ser. No. 09/918,267, filed Jul.30, 2001, issued as U.S. Pat. No. 6,931,665; the disclosures of whichare herein incorporated by reference in their entirety.

FIELD

This disclosure relates to retroreflective material, and moreparticularly retroreflective material for use on protective garments.

BACKGROUND

Retroreflective materials have been developed for use in a variety ofapplications, including road signs, license plates, footwear, andclothing patches to name a few. Retroreflective materials are often usedas high visibility trim materials in clothing to increase the visibilityof the wearer. For example, retroreflective materials are often added toprotective garments worn by firefighters, rescue personnel, EMStechnicians, and the like.

Retroreflectivity can be provided in a variety of ways, including by useof a layer of tiny glass beads or microspheres that cooperate with areflective agent, such as a coated layer of aluminum. The beads can bepartially embedded in a binder layer that holds the beads to fabric suchthat the beads are partially exposed to the atmosphere. Incident lightentering the exposed portion of a bead is focused by the bead onto thereflective agent, which is typically disposed at the back of the beadembedded in the binder layer. The reflective agent reflects the incidentlight back through the bead, causing the light to exit through theexposed portion of the bead in a direction opposite the incidentdirection.

Retroreflective materials can be particularly useful to increase thevisibility of fire and rescue personnel during nighttime and twilighthours. In some situations, however, firefighter garments can be exposedto extreme temperatures during a fire, causing the retroreflectivematerial to trap heat inside the garment. Under certain conditions, thetrapped heat can result in discomfort or even bums to the skin of thefirefighters In particular, moisture collected under the retroreflectivematerial may expand rapidly when exposed to the extreme temperature fromthe fire. If the expanded moisture is unable to quickly permeate throughthe retroreflective material, the firefighter can be exposed to extremetemperatures. In some cases, this can result in steam bums on the skinof the firefighter underneath the portions of the garment having theretroreflective material. Conventional retroreflective materials,including perforated retroreflective materials generally exhibit thisphenomenon. For example, conventional perforated retroreflectivematerials include standard retroreflective trim having needle punchedholes, laser punched holes, slits, or relatively large holes made with apaper punch.

SUMMARY

In general, this disclosure describes vapor permeable retroreflectivematerial for use on protective garments. For example, the material canbe formed on the protective garment in a non-continuous pattern thatprovides a high-level of retroreflective brightness, yet also providesadequate permeability to prevent exposure to heated moisture andprolonged exposure to extreme temperatures.

In particular, the non-continuous pattern may include retroreflectiveregions and non-retroreflective regions. The regions are arranged suchthat the retroreflective regions do not substantially decrease thermaldecay or vapor permeability. Rather, vapor permeability and thermaldecay through the protective garment may be substantially the same as ifthe retroreflective pattern was not present.

In one aspect, a garment includes a protective outer layer such as anouter shell of a firefighter outfit, and a reflective material formedover a first portion of the protective outer layer. The retroreflectivematerial can be formed in a non-continuous pattern to defineretroreflective regions and non-retroreflective regions. Thermal decaythrough the first portion may be substantially equal to thermal decaythrough a second portion of the protective garment not covered byretroreflective material. Alternatively or additionally, vaporpermeability through the first portion may be substantially equal tovapor permeability through a second portion of the protective garmentnot covered by retroreflective material. The garment may comprise anouter shell of a firefighter outfit and the first portion may compriseretroreflective trim on the outer shell of the firefighter outfit. Insome aspects, the first portion formed with the non-continuousretroreflective pattern may have a reflective brightness greater than 50candelas/(lux*meter²) or even greater than 250 candelas/(lux*meter²).

In another aspect, a protective outfit includes a first layer, a secondlayer and a third layer. The first layer may be an outer shell includinga non-continuous retroreflective portion that has retroreflectiveregions and non-retroreflective regions and a second portion that doesnot have retroreflective regions. Moreover, vapor permeability and/orthermal decay through the non-continuous retroreflective portion may besubstantially equal to vapor permeability through the second portion.The protective outfit may be a firefighter outfit in which the secondlayer is a moisture barrier and the third layer is a thermal liner.Alternatively, the protective outfit may be a thermal control outfit inwhich the second layer is a liquid retaining layer and the third layeris a waterproof vapor permeable layer. Again, the non-continuousretroreflective portion may have a reflective brightness greater than 50candelas/(lux*meter²) or even greater than 250 candelas/(lux*meter²).

In other aspects, an article may include a first material, such as adurable cloth backing made of the same material as an outer shell of afirefighter outfit. In addition, the article may include retroreflectivematerial formed on the first material according to a non-continuouspattern defining retroreflective regions and non-retroreflectiveregions,. The retroreflective material can be arranged such that it doesnot substantially decrease thermal decay through the article. Theseretroreflective regions and vapor permeable non-retroreflective regionsmay form any of a variety of different configurations as described ingreater detail below. The presence of the retroreflective regions maynot substantially decrease thermal decay and or vapor permeabilitythrough the article. In one particular case, the article comprises aretroreflective patch for use on a garment. The material defining thenon-continuous pattern may have a reflective brightness greater than 50candelas/(lux*meter²) or even greater than 250 candelas/(lux*meter²).

In still other aspects, this disclosure describes one or more methods.For example, a method may include screen printing an adhesive pattern ona protective garment and pressing retroreflective beads on the adhesivepattern to create a retroreflective pattern. Vapor permeability and/orthermal decay through the protective garment in portions having theretroreflective pattern may be substantially the same as vaporpermeability and/or thermal decay through the protective garment inportions of the garment that do not have the retroreflective pattern.

Alternatively, a method may include mixing retroreflective beads into anadhesive material and screen printing a pattern on a protective garmentusing the mixture. Again, vapor permeability and/or thermal decaythrough the protective garment in portions having the screened patternmay be substantially the same as vapor permeability and/or thermal decaythrough the protective garment in portions of the garment that do nothave the screened pattern.

Non-continuous vapor permeable material can provide several advantages.In particular, unlike conventional retroreflective material, includingperforated retroreflective material, the non-continuous vapor permeablematerial can provide improved thermal and vapor transfer throughprotective garments having retroreflective material thereon. Unlikeconventional perforated retroreflective material that can decrease vaporpermeability and thermal decay, this disclosure provides techniques forfixing retroreflective material to protective garments withoutsubstantially effecting the permeability of the garment, therebyreducing the risk of injury due to heated moisture and extremetemperatures. In addition, the techniques described herein can provideimproved thermal decay through an outer shell versus the use ofconventional retroreflective material, such as perforatedretroreflective material, thereby allowing any heat trapped within theprotective outfit to escape.

Other advantages of the non-continuous retroreflective material includethe ability to use highly retroreflective material on a protectivegarment without risking potential injury to the wearer of the garmentdue to extreme temperatures. The use of retroreflective material isparticularly important during nighttime and twilight hours whenvisibility is low. The disclosure below can provide for the creation ofnon-continuous retroreflective material having a reflective brightnessgreater than 50 candelas/(lux*meter²) or even greater than 250candelas/(lux*meter²) without substantially changing the vaporpermeability and thermal decay of the garment.

In addition, providing retroreflective material on protective outfitsusing screen printing techniques or other techniques described hereincan improve the production of protective outfits. Moreover, theretroreflective patterns created as described below may be thinner andmuch less bulky that more conventional retroreflective material used onconventional protective garments.

Additional details of these and other embodiments are set forth in theaccompanying drawings and the description below. Other features, objectsand advantages will become apparent from the description and drawings,and from the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a protective garment incorporating a non-continuousretroreflective material.

FIGS. 2-5 further illustrate exemplary non-continuous vapor permeableretroreflective patterns.

FIGS. 6 and 7 are flow diagrams illustrating processes for creatingmaterial having the non-continuous vapor permeable retroreflectivepatterns.

FIG. 8 is a cross-sectional view of a multi-layer firefighter outfitthat includes an outer shell incorporating a non-continuousretroreflective material.

FIGS. 9 and 10 are graphs summarizing experimental data collected intesting the vapor permeability of a protective garment.

FIGS. 11 and 12 are graphs summarizing experimental data collected intesting the thermal decay of heat escaping a protective garment.

FIG. 13 is a graph of temperature differentials between variouslocations of various firefighter outfits showing thermal transfercharacteristics of a garment incorporating non-continuous vaporpermeable material in comparison to the prior art.

FIG. 14 is a cross-sectional view of another protective outfitincorporating a non-continuous retroreflective material on an outershell.

DETAILED DESCRIPTION

In general, this disclosure describes vapor permeable retroreflectivematerial for use on protective garments. The material may include anon-continuous retroreflective pattern that provides a high-level ofretroreflective brightness, yet provides adequate permeability toprevent exposure to heated moisture and extreme temperatures.

In some cases, this disclosure describes the garment itself, i.e., anouter layer or outer shell of a protective outfit. In other cases, thisdisclosure describes an article, such as a clothing patch that could beadded to a protective garment. In still other cases, this disclosuredescribes a protective outfit that includes the non-continuousretroreflective pattern on an outer shell and additional layers such asa thermal liner and a moisture barrier.

The non-continuous retroreflective pattern may include retroreflectiveregions and non-retroreflective regions. However, unlike conventionalretroreflective material, the presence of retroreflective regions do notsubstantially decrease thermal decay or vapor permeability through thematerial. In other words, the thermal decay and vapor permeabilitythrough the material are not substantially reduced by theretroreflective pattern. Rather, vapor permeability and thermal decaythrough the material may be substantially the same as if theretroreflective pattern was not present. In general, vapor permeabilityis a measure of the transfer rate of vapor through a material. Thermaldecay is a measure of the rate at which heat can escape through amaterial.

FIG. 1 illustrates a protective garment 10 such as an outer shell of aprotective outfit worn by a firefighters Protective garment 10 includesan outer shell having retroreflective material formed in anon-continuous pattern over a first portion 12 to define retroreflectiveregions and non-retroreflective regions. A second portion 14 does nothave retroreflective regions. As described in greater detail below,thermal decay through the first portion 12 is substantially equal tothermal decay through the second portion 14. In addition, vaporpermeability through the first portion 12 is substantially equal tothermal decay through the second portion 14.

First portion 12 may include an article, such as a clothing patch formedwith a non-continuous retroreflective pattern, or alternatively,non-continuous retroreflective pattern may be printed directly onto thesurface of protective garment 10 as discussed below. Importantly, unlikeconventional retroreflective materials used with protective garments,first portion 12 does not trap heat or vapor inside protective garment10. Garment 10 may also include other non-retroreflective fluorescentmaterial (not illustrated) to provide improved visibility of garment 10during the day.

FIGS. 2-5 illustrate a number of exemplary non-continuous patterns ofretroreflective material formed on first portion 12. In particular,retroreflective material may be applied in these and similarnon-continuous patterns onto a patch or other material, which may besewn or otherwise attached to protective garment 10. For example, theretroreflective material may be applied by screen printing or by heattransferring the material from a tape-like substance as described below.In some aspects, the retroreflective material may be applied directlyonto protective garment 10 to realize first portion 12. Of course, thepatterns illustrated in FIGS. 2-5 are only exemplary, and other patternscould be used.

FIG. 2 illustrates an example non-continuous pattern 20 definingretroreflective regions 22 and vapor permeable non-retroreflectiveregions 24. In this arrangement, the retroreflective regions 22 and thevapor permeable non-retroreflective regions 24 form a checkerboard-likeconfiguration having a surface area of approximately fifty percentretroreflective material. In one particular case, the vapor permeablenon-retroreflective regions 24 and the retroreflective regions 22 havesides measuring approximately 0.3175 centimeters. In that case, theretroreflective regions have surface areas substantially less than onesquare centimeter.

Conventional retroreflective materials can substantially reduce vaporpermeability and thermal decay through garments. The use ofnon-continuous pattern 20 resolves this issue because the vaporpermeable non-retroreflective regions 24 comprise a sufficientpercentage of non-continuous pattern 20, allowing vapor and heat toescape. The presence of non-retroreflective regions 24, however, reducesthe reflective brightness of the pattern. For example, ifnon-retroreflective regions 24 account for 50 percent of the surfacearea of non-continuous pattern, the reflective brightness would beapproximately 50 percent less than it would be if retroreflectivematerials were applied in a continuous pattern.

The surface area of the non-retroreflective regions may need to compriseat least approximately 20% of a total surface area of theretroreflective material to ensure that vapor permeability and thermaldecay through the garment are not increased. The examples of FIGS. 2-5are all effective to allow vapor and heat to adequately escape.Non-retroreflective regions comprising greater than 20%, greater than25%, and greater than 50% of the total surface area of theretroreflective material may be particularly effective.

Another factor that can affect vapor permeability and thermal decay maybe the size of each individual retroreflective region and eachindividual non-retroreflective region. In particular, eachretroreflective region may need to be sufficiently small to ensure thatvapors and heat can escape through the material. Retroreflective regionshaving individual surface areas of less than four square centimeters andin some cases less than one square centimeter may be sufficient. Thiscan help ensure that thermal decay and vapor permeability throughportion 12 (FIG. 1) formed with the non-continuous retroreflectivepattern 20 (FIG. 2) is substantially the same as thermal decay and vaporpermeability through similar material, such as portion 14 that does nothave any retroreflective regions 22.

FIG. 3 illustrates an example non-continuous pattern 30 definingretroreflective regions 32 and vapor permeable non-retroreflectiveregions 34. In this arrangement, the retroreflective regions 32 and thevapor permeable non-retroreflective regions 34 form a stripe likeconfiguration. In other words, the non-retroreflective regions 34comprise stripe-like regions that separate the retroreflective regions32. The stripe-like configuration may have a surface area comprisingapproximately sixty-six percent retroreflective regions 32 andapproximately thirty-three percent vapor permeable non-retroreflectiveregions 34. In one particular case, the non-retroreflective regions 34are approximately 0.3175 centimeters wide and the retroreflectiveregions 32 are approximately 0.635 centimeters wide. Thermal decay andvapor permeability through portion 12 (FIG. 1) formed with thenon-continuous retroreflective pattern 30 is substantially the same asthermal decay and vapor permeability through similar material, such asportion 14 that does not have any retroreflective regions.

FIG. 4 illustrates an example non-continuous pattern 40 definingretroreflective regions 42 and vapor permeable non-retroreflectiveregions 44. In this arrangement, the retroreflective regions 42 and thevapor permeable non-retroreflective regions 44 form a pattern withtriangular shaped regions removed. In one case, the retroreflectiveregions 42 comprise approximately seventy-five percent of a surface areaof the non-continuous pattern 40. In another case, the retroreflectiveregions 42 comprise approximately fifty percent of a surface area of thenon-continuous pattern 40. Thermal decay and vapor permeability throughportion 12 (FIG. 1) formed with the non-continuous retroreflectivepattern 40 is substantially the same as thermal decay and vaporpermeability through similar material, such as portion 14 that does nothave any retroreflective regions. In still other aspects, both theretroreflective regions and the non-retroreflective regions comprisetriangular shaped regions.

FIG. 5 illustrates an example non-continuous pattern 50 definingretroreflective regions 52 and vapor permeable non-retroreflectiveregions 54. In this arrangement, the retroreflective regions 52 comprisecircular shaped regions within the non-retroreflective regions 54.Notably, thermal decay and vapor permeability through portion 12(FIG. 1) formed with the non-continuous retroreflective pattern 50 issubstantially the same as thermal decay and vapor permeability throughsimilar material, such as portion 14 that does not have anyretroreflective regions.

FIG. 6 is a flow diagram illustrating a screen printing process that canbe used to form non-continuous vapor permeable retroreflective patternslike those illustrated in FIGS. 2-5. As discussed above, the pattern canbe applied on a patch that can be sewn onto protective garment 10 (FIG.1). Alternatively, the pattern can be applied directly on a portion ofgarment 10, thereby forming non-continuous retroreflective portion 12.

Vapor permeable retroreflective material can be formed by defining anon-continuous pattern (62), mixing retroreflective glass beads into aresin (64) and screen printing the mixture onto an article according tothe defined pattern (66). The retroreflective beads may be half coatedwith aluminum. Suitable beads, for example, are #145 Reflective GlassElements commercially available from Minnesota Mining and ManufacturingCompany of St. Paul, Minn. After screen printing the mixture, the beadsare oriented randomly within the resin. After screen printing themixture, the mixture may be cured or dried according to a number oftechniques. The reflective brightness that can be achieved by theprocess of FIG. 6 may be only approximately 25 candelas/(lux*meter²) fortotal coverage because the beads are randomly oriented. Commonlyassigned U.S. Pat. No. 5,269,840 provides additional details of one ormore processes like that illustrated in FIG. 6, and is herebyincorporated herein by reference in its entirety.

Reflective brightness of retroreflective material is a measure of theapparent brightness of the article when viewed under standardretroreflective conditions, i.e., 0° orientation angle, −4° entranceangle, and 0.2° observation angle. The brightness is normalized for thearea of the article and the illumination from the light source used. Thereflectivity or reflective brightness is also referred to as thecoefficient of retroreflection (R_(A)), and is expressed in units ofcandelas/(lux*meter²). Reference is made to ASTM Standard Method#808-94, “Standard Practice For Describing Retroreflection.”

As mentioned above, the reflective brightness of the vapor permeableretroreflective material is related to the percentage of the surfacearea comprising retroreflective regions. For example, if the pattern hasa surface area defined by approximately fifty percent retroreflectiveregions and approximately fifty percent non-retroreflective regions, thereflective brightness may only be approximately 12.5candelas/(lux*meter²) if the technique of FIG. 6 is used. This may bebright enough for some applications, but not bright enough for others.For example, it can be desirable to maximize the reflective brightnessof firefighting garments to better ensure that firefighters are seen bymotorists during nighttime and twilight hours.

FIG. 7 illustrates a process that can be used to create non-continuousretroreflective patterns like that illustrated in FIGS. 2-5, wherein thereflective brightness is greater than 50 candelas/(lux*meter²). In somecases, the brightness can be greater than 250 candelas/(lux*meter²).

The process of FIG. 7 involves defining a pattern (72) and screenprinting an adhesive on a material according to the defined pattern(74). For example, the material may comprise a portion of a protectivegarment or the material may comprise a patch for use with a protectivegarment. Retroreflective beads are then pressed on the adhesive patternto create a retroreflective pattern (76).

Pressing the retroreflective beads on the adhesive pattern (76) can beperformed in a number of ways. In one case, glass beads are firstdeposited onto a substrate and the exposed surfaces of the beads arecoated with aluminum. The substrate is then pressed onto the screenedadhesive, fixing the beads in the adhesive. The substrate can then bepeeled back, leaving the half-aluminum coated beads properly oriented inthe adhesive. Such a method can achieve reflective brightness ofapproximately 500 candelas/(lux*meter²) for total coverage. Thus, if thepattern defines fifty percent coverage, the reflective brightness of thematerial may be approximately 250 candelas/(lux*meter²). If the patterndefines sixty-six percent coverage, the reflective brightness of thematerial may be approximately 330 candelas/(lux*meter²). If the patterndefines seventy-five percent coverage, the reflective brightness of thematerial may be approximately 375 candelas/(lux*meter²).

EXAMPLE 1

5720 3M™ Scotchlite™ Silver Graphic Transfer Film commercially availablefrom Minnesota Mining and Manufacturing Company of St. Paul, Minn.(hereafter 3M) was used to demonstrate non-continuous vapor permeableretroreflective material. Graphic images were made and transferred toKombat™ fabric comprising PVI/Kevlar® blended fabric available fromSouthern Mills of Union City, Ga. The fabric with the graphic images wasthen tested. The graphic images were used as one example of anon-continuous retroreflective pattern. Specifically, the sample wasprepared according to the following procedure.

The 5720 Silver Graphic Transfer Film (SFEE1134-3-2-1A with polyestercarrier) was screen printed with SX 779B FR Printable Adhesive (fireretardant SX 864B plastisol ink) available from Plast-O-Meric SP, Inc.,Sussex, Wis., modified with 3M™ 571N Coupler (A-1120 silane, 4% byweight). The ink was printed through a 110 T/in (43.3 T/cm) printingscreen with a medium hardness squeegee onto the 5720 Graphic TransferFilm using a Cameo printer available from American M & M Screen PrintingEquipment of Oshkosh, Wis. The artwork of the screen consisted of threestripes with different graphic patterns (checker board, hash-marks, andcircles). The resulting prints were gelled by passing them through aTexair™ Model 30 conveyor oven available from American Screen PrintingEquipment Co., Chicago, Ill., having a belt temperature of 230 degreesFahrenheit (110 degrees Centigrade). The oven was heated by an IR panelset at 1100 degrees Fahrenheit (593 degrees Centigrade), and the belttemperature was controlled by belt speed. After gelation, the printedgraphic images, were laminated to Kombat™ fabric using a HIX N-800 pressavailable from HIX Corp. of Pittsburg, Kans., set at 340 degreesFahrenheit (171 degrees Centigrade) for 30 seconds at an air linepressure of 40 psi (276 kPa). After the samples had cooled to roomtemperature, the polyester carrier was removed, yielding silver graphicimages on the Kombat™ fabric. This Kombat™ fabric, containing silverimages, was attached by sewing in the upper right-hand corner to theremaining two layers that make up the protective outfit shown in FIG. 8.This complete assembly was then tested according to a procedures thatsubstantially conformed standard industry testing procedures.

Another way of pressing the retroreflective beads on the adhesivepattern comprises depositing fully aluminum-coated beads onto theadhesive and then etching the aluminum from the exposed surfaces of thebeads. Such a process can be continuous, and the need to peel back anddiscard a substrate is avoided. Additional details of this process areprovided in copending and commonly assigned published PCT Applicationnumber WO0142823(A1), the entire content of which is hereby incorporatedby reference. The process can achieve a reflective brightness ofapproximately 350 candelas/(lux*meter²) or greater for total coverage.Thus, if the pattern defines fifty percent coverage, the reflectivebrightness of the material may be approximately 175candelas/(lux*meter²). If the pattern defines sixty-six percentcoverage, the reflective brightness of the material may be approximately231 candelas/(lux*meter²). If the pattern defines seventy-five percentcoverage, the reflective brightness of the material may be approximately263 candelas/(lux*meter²).

As yet another alternative to the processes of FIGS. 6 or 7, anon-continuous vapor permeable retroreflective material having patternslike those illustrated in FIGS. 2-5 can be created as follows. Glassbeads are first deposited and bonded onto a substrate and the exposedsurfaces of the beads are coated with aluminum. An adhesive is thenapplied on top of the glass beads, creating a retroreflective tape-likesubstance. The pattern can then be cut into the tape-like substancebefore pressing the tape-like substance onto a material such as a patchor the outer shell of a firefighter outfit. Heat and pressure can beapplied and the substrate can then be peeled back leaving the pattern ofhalf-aluminum coated beads properly oriented in the adhesive andattached to the underlying material to define the non-continuous vaporpermeable retroreflective material.

EXAMPLE 2

8710 3M™ Scotchlite™ Silver Transfer Film commercially available from 3Mwas also used to realize non-continuous vapor permeable material. 8710Silver Graphic Images were made and transferred to a Nomex® outer shellmaterial available from Southern Mills of Union City, Ga. The Nomex®outer shell material was then tested. The graphic images were used asanother example of a non-continuous vapor permeable retroreflectivematerial.

Specifically, the 8710 Silver Graphic Images were prepared according tothe following procedure. The 8710 Silver Transfer Film (75-0001-6745-4)graphic images were plotter cut, the weed was removed, and the materialwas then laminated to Nomex® outer shell material using a HIX N-800press available from HIX Corp. of Pittsburg, Kans., set at 338 degreesFahrenheit (170 Centigrade) for 15 seconds at an air line pressure of 40psi (276 kPa). After the samples had cooled to room temperature, thepaper carrier was removed, yielding silver graphic images on the Nomex®outer shell material. This material containing silver images wasattached (by sewing in upper right-hand corner) to other layers thatmake up a protective outfit. This complete assembly was then testedaccording to a procedures that substantially conformed standard industrytesting procedures.

Non-continuous vapor permeable retroreflective materials created asdescribed above exhibit thermal decay properties and vapor permeabilityproperties that have not been achieved in the prior art. In particular,the thermal decay and vapor permeability through non-continuousretroreflective material may be the same as the underlying material. Inother words, the addition of the patterns of retroreflective materialdoes not substantially alter either the vapor permeability of thematerial or the thermal decay through the material. For this reason, thenon-continuous vapor permeable retroreflective material can improve theperformance of protective firefighter garments.

Providing retroreflective material on protective garments using screenprinting techniques or non-continuous retroreflective tape likesubstances that are heat applied can improve the production processassociated with the creation of protective garments. Moreover, thenon-continuous retroreflective patterns may be thinner and much lessbulky that more conventional retroreflective material used onconventional protective garments. In addition, the resultantnon-continuous vapor permeable retroreflective material can benon-perforated, thus avoiding any perforation steps in the productionprocess.

FIG. 8 is a cross-sectional view a multi-layer protective firefighteroutfit. Firefighter outfit 80 includes an outer shell 82, having aretroreflective portion 84 thereon. Firefighter outfit 80 also includesmoisture barrier 86 and thermal liner 88. Retroreflective portion 84carries retroreflective material formed in a non-continuous pattern.Portion 84 may be a patch that is sewn or otherwise attached to outershell 82. Alternatively, portion 84 may include a non-continuousretroreflective pattern screened directly on outer shell 82 as describedabove.

Outer shell 82 represents a typical outer shell used in firefighterprotective outfits. For example, outer shell may protect the firefighterfrom scrapes or abrasions and may be coated with a water repellent orthe like. An example is Kombat™ fabric comprising PVI/Kevlar® blendedfabric available from Southern Mills of Union City, Ga.

Moisture barrier 86 can be used to keep liquid from penetrating intothermal liner 88. Older firefighter outfits used moisture barriers thatwere vapor impervious. However, newer designs have utilized moisturebarriers that are vapor permeable to provide added comfort to thewearer. If moisture barrier 86 is vapor permeable, hot vapors may beable to penetrate to the skin of the wearer, causing discomfort or burnsif the vapors cannot escape through the outer shell or through the outershell equipped with retroreflective material. Indeed, the use of vaporpermeable moisture barriers is one of the underlying reasons that calledfor the non-continuous vapor permeable retroreflective material. Anexample of a suitable vapor permeable moisture barrier is Crosstech™material on Nomex® pajama check material available from W. L Gore ofElkton, Md.

Thermal liner 88 can be used to protect the wearer from extremetemperatures. An example of a suitable thermal liner is Aralite®material including 100% Kevlar® batt with 100% Nomax® face cloth,available from Southern Mills of Union City, Ga.

FIGS. 9 and 10 are graphs summarizing experimental data collected intesting the vapor permeability of prior art firefighter garments andfirefighter garments making use of a retroreflective material formed ina non-continuous pattern. Reference is made to industry standard testingmethods described in Lawson, J. Randall and Twilley, William H.,“Development of an Apparatus for Measuring the Thermal Performance ofFirefighters Protective Clothing”, National Institute of Standards andTechnology, Gaithersburg, Md., 1999 (NISTIR 6400); and American Societyfor Testing and Materials, E162 “Standard Test Method for SurfaceFlammability of Materials Using a Radiant Heat Energy Source”, ASTMAnnual Book of Standards, Volume 04.07, West Conshohocken, Pa., 1997.The various testing and experiments described below substantiallyconformed to the industry standard testing methods described in theabove-mentioned references.

In particular, FIG. 9 illustrates the vapor permeability of a prior artconstruction that utilizes a retroreflective standard trim materialrather than a non-continuous vapor permeable retroreflective materialfor portion 84 (FIG. 8). FIG. 10 illustrates the vapor permeability of agarment utilizing retroreflective material formed in a non-continuouspattern on portion 84. In both cases, the respective garment wassubjected to heat, and temperatures at particular points within therespective garment were recorded over time.

Referring to FIG. 9, line 92 graphs temperature as a function of timemeasured at point C (FIG. 8) of a firefighter garment using a prior artretroreflective standard trim material rather than a non-continuousvapor permeable retroreflective material for portion 84. Similarly, line94 illustrates temperature measured at point D of a prior artfirefighter garment. Notably, after approximately 70 seconds, thetemperature at point C becomes hotter than the temperature at point D.This is due, at least in part, to the fact that hot vapors were unableto adequately permeate through the prior art retroreflective material,and were driven down through the vapor permeable moisture barrier 86 andcondensed, quickly raising the temperature at point C. In theexperiments, the mass transfer of hot vapors was visually apparent asmoisture condensed on the thermal liner 88 in the regions covered by theprior art retroreflective material. Notably, prior art retroreflectivematerial having perforations showed similar results.

Unlike conventional retroreflective material, the use of non-continuousretroreflective material for portion 84 resulted in the desired vaporpermeability. Referring to FIG. 10, line 102 graphs temperature as afunction of time measured at point C (FIG. 8) of a firefighter garmenthaving a non-continuous vapor permeable retroreflective material forportion 84. Line 104 graphs temperature as a function of time measuredat point D of a firefighter garment including retroreflective materialformed in a non-continuous pattern as described herein. As shown, thetemperature at point C remains cooler than the temperature at point D atall times, due to the dissipation of the hot vapors developed from waterretained under outer shell through portion 84. In other words, hotvapors were able to adequately permeate through non-continuousretroreflective material, i.e., portion 84.

FIGS. 11 and 12 are graphs summarizing experimental data collected intesting the thermal decay of heat escaping a firefighter garment. Again,industry standard testing methods were used. FIG. 11 shows the thermaldecay of a prior art construction that utilizes a retroreflectivestandard trim material rather than a non-continuous vapor permeableretroreflective material for portion 84. FIG. 12 illustrates the thermaldecay of a garment utilizing a non-continuous vapor permeableretroreflective material for portion 84.

Referring to FIG. 11, line 112 graphs temperature as a function of timemeasured at point A (FIG. 8) of a prior art firefighter garment. Again,the prior art firefighter garment utilized retroreflective standard trimmaterial rather than a non-continuous vapor permeable retroreflectivematerial for portion 84. Line 114 graphs temperature as a function oftime measured at point B of a prior art firefighter garment. In theexperiment, the firefighter garment was exposed to extreme temperaturesand then removed from proximity to the heat source and allowed to cool.In the graph, the point at time=X corresponds to the point in time whenthe garment was removed from the heat source.

As can be seen by comparing line 112 to line 114, the thermal decay ofthe temperature at point A is less than the thermal decay of thetemperature at point B. In other words, in the prior art firefightergarment it took longer for point A to cool off than it did for point Bto cool off. The reason is at least in part due to the fact that theprior art retroreflective standard trim material reduced the rate ofthermal decay through the outer shell. Heat was trapped inside thegarment longer in the regions that correspond to the prior artretroreflective standard trim material.

Referring now to FIG. 12, line 122 graphs temperature as a function oftime measured at point A (FIG. 8) of firefighter garment having anon-continuous vapor permeable retroreflective material for portion 84.Line 124 graphs temperature as a function of time measured at point B ofthe firefighter garment including retroreflective material formed in anon-continuous pattern as described herein. As can be seen by comparingline 122 to line 124, the thermal decay of the temperature at point A isapproximately the same as the thermal decay of the temperature at pointB. In other words, non-continuous vapor permeable retroreflectivematerial does not substantially decrease the thermal decay through theouter shell of the firefighter garment. Heat was not trapped inside thegarment for longer periods of time in the regions that correspond to thenon-continuous vapor permeable retroreflective material.

FIG. 13 is a graph of temperature differentials between points A and B(FIG. 8) for various different firefighter garments, i.e. a graph of thetemperature at point A minus the temperature at point B over time. InFIG. 13, the point of approximately time=0 corresponds to the point intime at which the garment is removed from proximity to a heat source andallowed to cool. Line 132 corresponds to a prior art firefighter garmentincorporating standard continuous non-perforated retroreflective trim.As can be seen by line 132, the temperature differential between thetemperature under the outer shell versus the temperature under the outershell with the standard retroreflective trim is relatively large. Forexample, after approximately 50 seconds, it was approximately 50 degreesCentigrade hotter behind the standard trim. Again, this is due to thefact that heat cannot adequately escape through the standardretroreflective trim.

Line 134 corresponds to a prior art firefighter garment incorporatingstandard continuous perforated retroreflective trim. As can be seen byline 134, the temperature differential between the temperature under theouter shell versus the temperature under the outer shell with thestandard continuous perforated retroreflective trim is still relativelylarge. In other words, perforations do not resolve the thermal decayissue. For example, after approximately 50 seconds, it was approximately42 degrees Centigrade hotter behind the standard continuous perforatedretroreflective trim. Again, this is due to the fact that heat cannotadequately escape through the standard continuous perforatedretroreflective trim.

Line 136 corresponds to a firefighter garment, incorporating anon-continuous vapor permeable retroreflective material for portion 84(FIG. 8). As can be seen by line 136, the temperature differentialbetween the temperature under the outer shell both with and without thenon-continuous retroreflective material is much smaller than that oflines 132 or 134. In other words, non-continuous vapor permeableretroreflective material resolved the thermal decay issue. For example,after approximately 50 seconds, it was only approximately 4 degreesCentigrade hotter behind the non-continuous vapor permeableretroreflective material compared to the underlying material not havingretroreflective material formed thereon. Moreover, after 50 seconds, itwas never more than 8 degrees Centigrade hotter behind thenon-continuous vapor permeable retroreflective material. This is due tothe fact that heat can adequately escape through the non-continuousvapor permeable retroreflective material.

The graphs of FIGS. 9-13 illustrate the advantages of retroreflectivematerial formed in a non-continuous pattern, in relation to the priorart. The retroreflective material formed in a non-continuous pattern asdescribed herein provides improved thermal transfer and/or vaportransfer through protective garments having retroreflective materialthereon. Conventional retroreflective material, such as retroreflectivetrim materials and perforated retroreflective trim materials provideinadequate thermal decay and vapor permeability characteristics.Non-continuous vapor permeable retroreflective material, however,exhibits substantially the same thermal decay characteristics and vaporpermeability characteristics as the underlying material without theretroreflective material.

Firefighter garments, and thus multi-layer firefighter outfits, can begreatly improved by implementing non-continuous vapor permeableretroreflective material. If vapor cannot escape thought the outer shellbecause conventional retroreflective material provides a vapor barrier,hot vapors can be directed inward, toward the skin of the wearer,possibly causing steam burns or other discomfort to the wearer. Thetechniques described herein resolve this issue by providing aretroreflective material formed in a non-continuous pattern to defineretroreflective regions and non-retroreflective regions. In this manner,the addition of retroreflective material does not substantially decreasevapor permeability of the outer shell.

Thermal decay through an outer shell having conventional retroreflectivetrim material, such as perforated retroreflective trim material, issubstantially less than thermal decay through the outer shell in regionsnot having the conventional retroreflective trim material. Thus, heattrapped within the protective garment may not be able to escape fastenough for the firefighter to cool off at a desired rate. Rather, thepresence of conventional retroreflective material such as perforatedretroreflective trim material can cause heat to remain trapped insidethe protective garment for longer periods of time, providing discomfortto the firefighter even after he or she has left the fire. Thetechniques described herein resolve this issue by providing anon-continuous vapor permeable retroreflective material that does notsubstantially decrease thermal decay of the garment in the portionshaving the non-continuous vapor permeable retroreflective material. Inthis manner, the vapor permeable retroreflective material can reduce theheat load within the various layers that comprise the firefighteroutfit, reduce negative physiological impacts on the wearer, and reducethe likelihood of producing burn injuries on the wearer.

The techniques described herein can provide non-continuous vaporpermeable retroreflective material having a reflective brightnessgreater than 50 candelas/(lux*meter²) or even greater than 250candelas/(lux*meter²). Brightnesses in these ranges significantlyincrease visibility of a wearer during nighttime and twilight hours.Indeed, this can better ensure that firefighters are not only seen bynight motorists, but more importantly, these brightness ranges can beachieved while still providing the vapor permeability and thermal decaycharacteristics described above.

FIG. 14 is a cross-sectional view of another protective multi-layeroutfit that could benefit by the teaching of this disclosure. Protectiveoutfit 140 is a protective multi layer thermal control outfit.Protective outfit 140 includes an outer shell 142, and a non-continuousvapor permeable retroreflective material defines portion 144 of outershell 142. For example, portion 144 may be a patch that is sewn orotherwise attached to outer shell 142, or alternatively, portion 144 maybe a portion of outer shell 142 having a non-continuous retroreflectivepattern applied thereon as described above. Protective outfit 140 alsoincludes liquid retaining layer 146 and waterproof vapor permeable layer148.

Protective outfit 140 may be used to keep the wearer cool through theeffects of evaporative cooling and by acting as a heat sink. The liquidretaining layer 146 can be soaked with water and water vapors canpermeate through the outer shell 142 to cool the skin of the wearer. Theoutfit makes use of non-continuous vapor permeable retroreflectivematerial to define portion 144 of outer shell 142. In this manner, thethermal transfer characteristics and vapor permeability characteristicsof protective outfit 140 can be maintained while adding the effects ofnighttime visibility through the use of retroreflective materials.

A number of implementations and embodiments have been described. Forinstance, non-continuous vapor permeable retroreflective material havingretroreflective regions and non-retroreflective regions has beendescribed. Thermal decay and vapor permeability through thenon-continuous vapor permeable retroreflective material is substantiallythe same as thermal decay and vapor permeability through the underlyingmaterial that does not include non-continuous vapor permeableretroreflective material.

Nevertheless, it is understood that various modifications can be madewithout departing from the spirit and scope of this disclosure. Forexample, the non-continuous vapor permeable retroreflective materialcould be included in as part of any garment to provide retroreflectivelyin the garment and yet also provide adequate thermal decay and vaporpermeability through the garment. In addition, the non-continuous vaporpermeable retroreflective material could substantially or completelycover a garment or article. Also, the retroreflective material may bemade florescent to enhance daytime visibility. In addition, alternativemethods may be used to realize non-continuous vapor permeableretroreflective material. For example, various different graphic screenprinting techniques, electronic digital printing techniques, plottercutting, laser cutting, or die cutting of retroreflective substrates tobe applied on a material, or other similar techniques may be used torealize non-continuous vapor permeable retroreflective material.Accordingly, other implementations and embodiments are within the scopeof the following claims.

1. An article comprising: a first material; and retroreflective materialformed on at least a portion of the first material in a non-continuouspattern to define retroreflective regions and non-retroreflectiveregions arranged such that vapor permeability through the at least aportion formed with retroreflective material is substantially equal tovapor permeability through the first material without retroreflectivematerial.
 2. The article of claim 1, wherein the non-continuous patternincludes discrete retroreflective regions, such that at least one of theretroreflective regions is separated by a non-retroreflective regionfrom an adjacent retroreflective region.
 3. The article of claim 2,wherein the retroreflective regions and the non-retroreflective regionsform a stripe-like configuration.
 4. The article of claim 2, wherein theretroreflective regions include generally circular shaped regions withinthe non-retroreflective regions.
 5. The article of claim 1, wherein thenon-continuous pattern includes discrete non-retroreflective regions,such that at least one of the non-retroreflective regions is separatedby retroreflective material from an adjacent non-retroreflective region.6. The article of claim 5, wherein the retroreflective regions and thenon-retroreflective regions form a stripe-like configuration.
 7. Thearticle of claim 5, wherein the non-retroreflective regions includegenerally triangular shaped regions removed from the retroreflectivematerial.
 8. The article of claim 5, wherein the retroreflective regionsinclude generally circular shaped regions within the non-retroreflectiveregions.
 9. The article of claim 1, wherein the non-continuous patternincludes at least one retroreflective region that is connected to anadjacent retroreflective region.
 10. The article of claim 9, wherein theretroreflective regions and the non-retroreflective regions form acheckerboard-like configuration.
 11. The article of claim 9, wherein thenon-retroreflective regions include generally triangular shaped regionsremoved from the retroreflective material.
 12. The article of claim 9,wherein the retroreflective regions include generally circular shapedregions within the non-retroreflective regions.
 13. The article of claim1, wherein a surface area of the non-retroreflective regions comprisesat least 20% of a total surface area of the retroreflective material.14. The article of claim 1, wherein a surface area of thenon-retroreflective regions comprises at least 50% of a total surfacearea of the retroreflective material.
 15. The article of claim 1,wherein a surface area of each retroreflective region is less than foursquare centimeters.
 16. A garment comprising: an outer layer; andretroreflective material formed over a portion of the outer layer in anon-continuous pattern to define retroreflective regions andnon-retroreflective regions arranged such that vapor permeabilitythrough the portion formed with retroreflective material issubstantially equal to vapor permeability through the protective outerlayer without retroreflective material.
 17. The article of claim 16,wherein the outer layer comprises an outer shell of a firefighteroutfit.
 18. The article of claim 16, wherein the outer layer comprisesan outer shell of a multi-layer thermal control outfit.